Systems and methods for custom object design

ABSTRACT

Systems and methods disclosed herein include a first scanner comprising an inflatable membrane configured to be inflated with a medium to conform an exterior surface of the inflatable membrane to an interior shape of a cavity, the medium attenuating, at a first rate per unit length, light having a first optical wavelength, and attenuating, at a second rate per unit length, light having a second optical wavelength; an emitter configured to illuminate an interior surface of the inflatable membrane; a detector configured to receive light from the interior surface; a processor configured to generate a first electronic representation of the interior shape based on the received light; and a design computer configured to modify the first electronic representation into a three-dimensional shape by correlating pixels of the first electronic representation with corresponding distance information from the first scanner to the inflatable membrane for each pixel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/797,631 (Attorney Docket No. LANT-0301-U01-001-001), filed Feb. 21,2020, and entitled “SYSTEMS AND METHODS FOR USING NATIVE REFERENCES INCUSTOM OBJECT DESIGN”.

U.S. patent application Ser. No. 16/797,631 (Attorney Docket No.LANT-0301-U01-001-001) is a continuation of U.S. patent application Ser.No. 16/132,055 (LANT-0301-U01-001), filed Sep. 14, 2018 and entitled“CUSTOM EARBUD SCANNING AND FABRICATION”, now U.S. Ser. No. 10/616,560.

U.S. patent application Ser. No. 16/132,055 (LANT-0301-U01-001) is acontinuation of U.S. patent application Ser. No. 15/289,061 (AttorneyDocket No. LANT-0301-U01), filed Oct. 7, 2016, and entitled “CUSTOMEARBUD SCANNING AND FABRICATION”, now U.S. Ser. No. 10/122,989.

U.S. patent application Ser. No. 15/289,061 (Attorney Docket No.LANT-0301-U01), filed Oct. 7, 2016 claims the benefit of priority toU.S. Provisional Patent Application Ser. No. 62/239,811 (Attorney DocketNo. LANT-0301-P01), filed Oct. 9, 2015, and entitled “CUSTOM EARBUDSCANNING AND FABRICATION”.

Each of the foregoing applications is incorporated herein by referencein its entirety.

FIELD

The subject matter described herein relates to producing earbuds andearbud adapters customized to an individual ear.

BACKGROUND

Earbuds must be comfortable and provide a snug fit to provide the bestsound quality and reduce ambient noise. To provide a comfortable andsnug fit, customized earbuds may be produced that are based the actualshape of an ear. Traditional methods of determining the actual shape ofan ear cavity include creating an impression of the ear canal. Creatingor taking an impression includes injecting a material into the earcavity or canal. The material is allowed to harden and conform to theshape of the cavity, and then the material is extracted from the cavity.An impression created this way may cause complications or pain when theimpression material is injected into the cavity, when the material ishardening, or when the impression is extracted.

SUMMARY

In one aspect, a first scanner includes an inflatable membraneconfigured to be inflated with a medium to conform an exterior surfaceof the inflatable membrane to an interior shape of a cavity. The mediumattenuates, at first rate per unit length, light having a first opticalwavelength, and attenuates, at a second rate per unit length, lighthaving a second optical wavelength. The scanner also includes an emitterconfigured to generate light to illuminate the interior surface of theinflatable membrane and a detector configured to receive light from theinterior surface of the inflatable membrane. The received light includeslight at the first optical wavelength and the second optical wavelength.The scanner further includes a processor configured to generate a firstelectronic representation of the interior shape based on the receivedlight. The system includes a design computer configured to modify thefirst electronic representation into a three-dimensional shapecorresponding to at least a portion of the interior shape and afabricator configured to fabricate, based at least on the modified firstelectronic representation, an earbud.

In some variations, one or more of the following features can optionallybe included in any feasible combination.

The first scanner may include a scanning tip. The scanning tip mayinclude the emitter and the detector. The scanning tip may be configuredto actuate between an extended position and a retracted position.

The second scanner may include a structured light source and a camera.The second scanner may be configured to generate a second electronicrepresentation of a second shape. The second shape may be of at leastone of: a second interior shape of a portion of the cavity and a secondportion of a second surface proximate to the cavity. The second scannermay be coupled to the first scanner.

The design computer may be further configured to merge the firstelectronic representation and the second electronic representation intoa combined electronic representation of the interior shape and thesecond shape. The design computer may execute a computer-aided designapplication.

The fabricator may include at least one of: a mold for the earbud, themold based at least on the interior shape, a three-dimensional printeror digital light processing system, and a second apparatus configured toadd one or more additional components to the earbud. The one or moreadditional components may include at least one component for deliveringsound to an area proximal to the earbud.

The three-dimensional printer may be configured to fabricate an objectcomprising a shell with a predetermined thickness, and where the shellcorresponds to the interior shape.

A silicone injector may be configured to inject silicone inside of theshell. The silicone may have a hardness between 15 and 75 shore aftercuring.

In an interrelated aspect, a method includes performing a first scan,with at least a first scanner, of an interior shape of a cavity. Thefirst scan of the interior shape includes inflating an inflatablemembrane with a medium. The inflating of the inflatable membraneconforms an exterior surface of the inflatable membrane to the interiorshape of the cavity. The first scan also includes generating light froman emitter to at least illuminate the interior surface of the inflatablemembrane. The first scan further includes detecting, at a detector,light from the interior surface of the inflatable membrane. The lighthas a first optical wavelength and a second optical wavelength. Thefirst scan also includes generating, at a processor, a first electronicrepresentation of the interior shape. The generating is based at leaston the detected light.

A second scan of a second shape proximate to the cavity is performed.The second scan of the second shape generates a second electronicrepresentation of the second shape.

A design computer modifies the first electronic representation into athree-dimensional shape corresponding to at least a portion of theinterior shape. The design computer generates a combined electronicrepresentation including the first electronic representation and thesecond electronic representation. The fabricator fabricates an earbud.The fabricating is based at least on the combined electronicrepresentation.

In yet another interrelated aspect, a method includes performing a firstscan, with at least a first scanner, of an interior shape of a cavity.The first scan of the interior shape includes detecting, at a detector,light comprising a first optical wavelength and a second opticalwavelength. The detected light is generated by at least one of:detecting structured light generated from a pattern imprinted on aninterior surface of an inflatable membrane and emitting, by the emitter,structured light to form a pattern on the interior surface of theinflatable membrane conforming to an interior shape of an ear and thedetected light generated by reflection of the structured light from theinterior surface. A processor generates a first electronicrepresentation of the interior shape. The generating is based at leaston the detected structured light;

A second scan of a second shape proximate to the cavity is performed.The second scan of the second shape generates a second electronicrepresentation of the second shape. A design computer modifies the firstelectronic representation into a three-dimensional shape correspondingto at least a portion of the surface. The design computer generates acombined electronic representation including the first electronicrepresentation and the second electronic representation. A fabricatorfabricates an earbud. The fabricating is based at least on the combinedelectronic representation.

In some variations, one or more of the following features can optionallybe included in any feasible combination.

The second scan may be performed by a second scanner. The second scannermay include at least one of the first scanner, a structured light sourceand a camera, and a laser rangefinder.

The scanning tip may actuate between an extended position and aretracted position. The actuation may include the emitter and thedetector and the scanning tip being actuated during the generation anddetection of the light.

A surface may be illuminated with a structured light source, thestructured light source emitting light having spatial variations ofintensity or wavelength. The illuminated surface may be imaged with acamera, the imaging generating one or more images resulting from thespatially varying light. The second electronic representation of thesurface may be generated based at least on the one or more images.

The first electronic representation may be generated based at least onmeasurements of absorption of the light at the first optical wavelengthand measurements of absorption of the light at the second opticalwavelength.

The combined electronic representation may correspond to a concha regionof an ear and at least a portion of an ear canal.

One or more native references within the first shape and the secondshape may be identified based on at least the second electronicrepresentation.

A number of electronic representations may be combined based at least onthe one or more native references.

The fabricating may include at least one of: forming, based at least onthe interior shape, a mold for the earbud, fabricating the earbud with athree-dimensional printer or a digital light processing system, andadding, with a second apparatus, one or more additional components tothe earbud. The one or more the additional components may include atleast one component for delivering sound to an area proximal to theearbud.

The fabricating may further include fabricating, with thethree-dimensional printer, an object having a shell with a predeterminedthickness. The shell may correspond to the interior shape. Silicone maybe injected inside of the shell with a silicone injector. The siliconeinjected inside of the shell may be cured. The shell may be removed toform the earbud.

The above-noted aspects and features may be implemented in systems,apparatus, methods, and/or articles depending on the desiredconfiguration. The details of one or more variations of the subjectmatter described herein are set forth in the accompanying drawings andthe description below. Features and advantages of the subject matterdescribed herein will be apparent from the description and drawings, andfrom the claims.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings,

FIG. 1 is a diagram illustrating an example of a system including athree-dimensional (3D) scanner having an inflatable membrane, inaccordance with some example embodiments;

FIG. 2 is a diagram illustrating an example 3D rendering of a cavityformed based on scanner data collected and processed by the 3D scanner,in accordance with some example embodiments;

FIG. 3 is a diagram illustrating the 3D scanner with a scanning tip inan extended position, in accordance with some example embodiments;

FIG. 4 is a diagram illustrating the 3D scanner with a scanning tip in aretracted position, in accordance with some example embodiments;

FIG. 5 is a diagram illustrating the attenuation of reflected light by amedium in the inflatable membrane, in accordance with some exampleembodiments;

FIG. 6 is a diagram illustrating membrane-less determination of thedistance to a proximal location of an inner surface of the ear, inaccordance with some example embodiments.

FIG. 7 is a diagram illustrating membrane-less determination of thedistance to a distant location of an inner surface of the ear, inaccordance with some example embodiments.

FIG. 8 is a diagram illustrating an exemplary reflectance spectra of aportion of an ear, in accordance with some example embodiments;

FIG. 9A, FIG. 9B, and FIG. 9C are diagrams illustrating a serial linkagebetween a structured light source and camera, in accordance with someexample embodiments;

FIG. 10A, FIG. 10B, and FIG. 10C are diagrams illustrating imaging a 3Dobject with a structured light source and camera, in accordance withsome example embodiments;

FIG. 11 is a process flow diagram illustrating combining a scan from a3D scanner and another scan from a structured light source and camera,in accordance with some example embodiments;

FIG. 12 is a diagram illustrating an example transition region betweenexample scans from a 3D scanner and a structured light source andcamera, in accordance with some example embodiments;

FIG. 13A and FIG. 13B are diagrams illustrating examples of earbudadapters, in accordance with some example embodiments;

FIG. 14 is a process flow diagram illustrating a first process, inaccordance with some example embodiments;

FIG. 15 is a process flow diagram illustrating a second process, inaccordance with some example embodiments; and

FIG. 16 is a process flow diagram illustrating a third process, inaccordance with some example embodiments.

Like labels are used to refer to same or similar items in the drawings.

DETAILED DESCRIPTION

An earbud is an object customized to fit the interior shape and exteriorshape of a particular person's ear. The earbud may be made of a soft orflexible material in order to be comfortable for the person to wear theearbud in their ear. The earbud may include a speaker or other soundgenerating device. An earbud adapter may be an object with customizedshape to fit the interior or exterior of a particular person's ear. Inaddition to being customized to fit the ear, it may also customized tofit a commercial earbud or other sound generating device. The commercialearbud may be held into place in the earbud adapter by a clip, latch, orlip of earbud material that holds the commercial earbud in place in theearbud adapter so that the earbud adapter and commercial earbud operateas one object. For example, an earbud adapter may be customized toattach to an earbud and conform to a particular ear. A custom earbud orearbud adapter may provide a more comfortable fit, stay in the ear moresecurely, provide better sound quality to the person, and/or reduce theambient noise that passes through or past the earbud.

Some example embodiments, may include a process for generating a customearbud and/or earbud adapter. The process may include scanning orscoping and measuring the ear canal with an optical scanner. Based onthe scan, a mechanical device, such as an earbud, earbud adapter, orearbud shell may be produced from the scan information. An earbud shell(also referred to as a shell) may include a shell made from a thin layerof rigid material formed into the shape of the surface scanned, forexample, the ear/ear canal. The earbud shell may serve as a mold inwhich flexible material is injected and allowed to cure in the shape ofthe mold and corresponding ear. In some example embodiments, the shellmay comprise polyamide and/or urethane. Other materials may be used aswell. In some example embodiments, the shell may be produced using athree-dimensional printer to lay down layers of polyamide, urethane, orother material to produce the earbud shell. Although the followingdisclosure applies to earbuds and earbud adapters, the following mayalso apply to sleeping plugs and/or noise plugs.

Before providing additional details with respect to exemplary processesfor making earbuds or earbud adapters (for example, silicon or rubberytips or covers that can be coupled to a commercial earbud), thefollowing describes an example of an optical scanner that can be usedfor scanning the ear.

FIG. 1 is a diagram illustrating an example of a system 100 including athree-dimensional (3D) scanner having an inflatable membrane 110, inaccordance with some example embodiments of the current subject matter.The system 100 and accompanying software may generate three-dimensional(3D) scans of a cavity, such as an ear cavity. System 100 may include a3D scanner 120 including inflatable membrane 110 and a processor, suchas a computer. The processor may process scanner data generated by 3Dscanner 120 during a scan of the cavity. The processor may form anoutput, such as a 3D impression of the scanned cavity.

FIG. 2 is a diagram illustrating an example 3D rendering of a cavityformed based on scanner data collected and processed by the 3D scanner120, in accordance with some example embodiments. The 3D surface, alsoreferred to herein as an electronic representation 200, may model thescanned cavity, such as an ear cavity, and this 3D surface may beprovided to a manufacturer, 3D printer, and the like to form an object.In the case of the ear, the object may be an earpiece or earbud/earbudadapter.

As used herein, the terms “earbud,” “earpiece,” and “earbud adaptor” caninclude any sort of appliance that may be worn on the ear, in the ear,or any combination thereof. For example, this may include earbuds forspeakers, wireless transmitter/receivers hooked over the ear, earplugs,headphones, personal hearing protection, hearing aids, or the like.

More generally, the terms “earbud,” “earpiece,” and “earbud adaptor” mayalso refer to any appliance or object that may be manufactured toconform to any cavity or internal space scanned by any of the scanningtechniques described herein. Many of the implementations describedherein refer to scanning an ear as part of a process of manufacturing anearbud. However, these implementations do not exclude using any of theapparatus or techniques described herein for the manufacture of otherobjects, apparatuses, tools, or the like.

FIG. 3 is a diagram illustrating the 3D scanner 120 with a scanning tip320 in an extended position, in accordance with some exampleembodiments. FIG. 4 is a diagram illustrating the 3D scanner 120 with ascanning tip 320 in a retracted position, in accordance with someexample embodiments. A medium 310 may be used to inflate and expand theinterior of the inflatable membrane 110 so that the inflatable membrane110 conforms an external surface of the inflatable membrane 110 to aninterior shape of a cavity 330, or portion of the cavity 330, or anyother cavity 330 or surface being scanned.

For example, the medium 310 may be inserted into the inflatable membrane110, so that inflatable membrane 110 conforms to the cavity 330 beingscanned. At this point, scanning tip 320 may scan the interior surfaceof the inflatable membrane 110 which, when inflated with the medium 310,conforms an external surface of the inflatable membrane 110 to aninterior shape of the cavity 330. The interior shape can be, forexample, the interior shape of an ear or other object. The scanning tip320, which may include a light emitter and detector, can actuate betweenan extended position and a retracted position during the generation anddetection of the light used for scanning. In this way, scanning tip 320may scan the interior surface of the inflatable membrane 110 and thuscavity 330. The scanning tip 320 may generate a 2D image of theinflatable membrane approximating a snap shot of the cavity 330. Eachpixel of the 2D image may then be associated with distance informationobtained during a scan, for example, the distance from the scanning tip320 to the scanned portion of the membrane. The combination of the 2Dimage and distance information for each pixel of the 2D image maycorrespond to 3D data (for example, a 3D surface representative of thescanned cavity 330). In some implementations, the distance informationdetermined from scanning data can correlate to groups of pixels, insteadof a single pixel, on the 2D image.

Medium 310 may, for example, be a liquid, a dissolved gas, a gel, ahydrogel, and/or any combination of the four. The medium 310 may includeadditives dissolved into, or suspended in, the medium 310 to provideproperties. These properties may include, for example, such as selectiveabsorption where one or more wavelengths of light are absorbed more thanone or more other wavelengths. To illustrate, medium 310 may include acolored dye, suspension, a luminescent substance, and/or a fluorescentsubstance (and/or any other material having selective attenuationproperties). The medium 310 may also contain a bio-neutralizing,anti-microbial, or anti-oxidizing agent to improve the shelf life of themedium 310 as well as a buffering agent to improve the stability of themedium 310. Moreover, the selective attenuation properties may, asdescribed further below, allow 3D scanner 120 and/or processor todetermine the shape of, distance to, and/or other properties of thescanned interior surface of inflatable membrane 110.

The inflatable membrane 110 may be implemented as any viscoelastic,elastic, plastic, and/or any other material that may be inflated toconform to the ear cavity 330, when the inflatable membrane 110 isinserted into the cavity 310 and inflated with medium 310. When thecavity 330 corresponds to an ear canal, inflatable membrane 110 may havean inflated 3D shape and size that is substantially adapted to the earcavity 330. The inflatable membrane 110 may be used with other cavitiesand forms, for example, a stomach, an esophagus, a bladder, and or thelike. The inflatable membrane 110 may also include, or be coated with, amaterial to make the membrane fluoresce light of a particularwavelength, or a range of wavelengths, as further described below. Insome implementations, the inflatable membrane may have a balloon-likeshape with an opening, an interior surface, and an exterior surface. Insome implementations, scanning the inflatable membrane 110, rather thanthe ear cavity 330 directly, may reduce (if not eliminate) theinterference caused by artifacts, such as ear hair, wax, and the like,and may thus improve the accuracy of the cavity measurement scan.

FIG. 5 is a diagram illustrating the attenuation of reflected light by amedium 310 in the inflatable membrane 110, in accordance with someexample embodiments. The 3D scanner 120 and/or the scanning tip 320 mayinclude at least one light source, such as a light emitting diode, foremitting light into the inflatable membrane 110, which may or may notinclude medium 310. In FIG. 5, the emitted light 510 is represented bythe arrows going out from the scanning tip 320. The scanning tip 320 mayalso collect and/or detect light 520 and 530 that is emitted fromfluorescent material in, or on, the inflatable membrane 110. The light510 emanating from scanning tip 320 may comprise light used to excitethe fluorescent material in, or on, the inflatable membrane 110.Further, light from the fluorescent material in, or on, the inflatablemembrane 110 may be referred to as “fluoresced” light, i.e., lightresulting from the interaction of the fluorescent material with thelight 510 from scanning tip 320.

The inflatable membrane 110 may include a fluorescent material, such asone or more fluorescent dyes, pigments, or other coloring agents. Thefluorescent material can be homogenously dispersed within the inflatablemembrane 110, although the fluorescent material may be applied in otherways as well (for example, the fluorescent material may be pad printedonto the surface of the inflatable membrane). The fluorescent materialmay be selected so that the fluorescent material is excited by one ormore wavelengths of light 510 emitted by the scanning tip 320. Once thefluorescent material is excited by light 510, the fluorescent materialmay emit light at two or more wavelengths λ₁, λ₂, or a range ofwavelengths. For example, wavelength λ₁ may represent a range ofwavelengths associated generally with red, although wavelength λ₁ may beassociated with other parts of the spectrum as well.

In some implementations, the medium 310 may differentially attenuate,for example based on wavelength or other property, light passing throughthe medium 310. For example, as the two or more wavelengths of light 520propagate through the medium 310 along paths l₁ and l₂, l₁≠l₂, themedium 310 may absorb one or more of the wavelengths of light λ₁, λ₂ toa greater degree than one or more other wavelengths of the light. Themedium 310 used in the system 100 may also be selected to optimally andpreferentially absorb one or more of the wavelengths or a range ofwavelengths of light from the fluorescent material of the inflatablemembrane. By selecting a medium 310 that complements the fluorescentmaterial, the scan data collected by the 3D scanner 120 may be moreaccurate.

Similar to the process described with reference to FIG. 3, when thescanning tip 320 of 3D scanner 120 is inserted into ear cavity 330, 3Dscanner 120 may pump (or insert in other ways) medium 310 intoinflatable membrane 110 until the inflatable membrane 110 conforms tothe interior surface of the cavity 330. Once the inflatable membrane 110is fully inflated, 3D scanner 120 and/or scanning tip 320 may emit light510 with an emitter, for example a light emitting diode. Light 510 maytravel from the scanning tip 320, through medium 310, and excite thefluorescent material on, or in, a portion of the inflatable membrane110. The light 520, 530 emitted from the fluorescent material on, or in,the inflatable membrane 110 may include at least two wavelengths oflight, λ₁, and λ₂. One of the wavelengths of light or some ranges ofwavelengths of light emitted by the fluorescent material may bedifferentially attenuated by the medium 310. The differentialattenuation may be due to the medium 310 attenuating light at a firstoptical wavelength λ₁ at first rate per unit length μ₁, and attenuatinglight at a second optical wavelength λ₂ at a second rate per unit lengthμ₂. The attenuation can be described, for example, as

I ₁(x)=I ₁(0)e ^(−μ) ¹ ^(x)  (1)

for the attenuation of the intensity of light at wavelength λ₁ and

I ₂(x)=I ₂(0)e ^(−μ) ² ^(x)  (2)

Here, the initial intensity, for example at the point of emission fromthe fluorescent material, is I₁(0) or I₂(0). As the light propagatesthrough the medium 310 a distance x along a path between the point ofemission and the scanning tip 320, the light may be reduced in intensityor attenuated by the medium 310. The attenuation may be due to, forexample, absorption, reflection, scattering, diffraction, or the like.

The light having wavelengths λ₁, λ₂ or wavelength ranges of light, maythen be received by a detector. The detector may be integrated with thescanning tip 320 and may be configured to receive light from theinterior surface of the inflatable membrane 110. The ratio of theintensities of light λ₁, λ₂ or the ratio of the integral area of lightfound under specific ranges may be measured and recorded by 3D scanner120 and/or processor to determine a distance from the scanning tip 320to corresponding surface of the membrane 110. For example, the distancex may be determined by inverting Eqns. (1) and (2). The scanning tip 320may move throughout the interior of inflatable membrane 110 to scanvarious portions of the interior surface of the inflatable membrane 110.The scanning tip 320 may receive the fluoresced wavelength of light 520,130 in order to collect data that may be used by the 3D scanner 120and/or processor to generate an electronic representation 200 of aninterior shape of the ear to form a 3D surface representative of thecavity 330. Alternatively, or additionally, the scanning tip 320 mayinclude optical, electronic, or mechanical components for focusing anddirecting the light used to excite the fluorescent material. Althoughthe scanning tip 320 may include one or more components, such as one ormore light emitting diodes, optics, lenses, detectors/CCDs/CMOS sensors,and the like, one or more of these components may be located in otherportions of the 3D scanner 120 (for example, an optical fiber may carrylight 510 to scanning tip 320).

In some example embodiments, the 3D scanner 120 in accordance with FIGS.1-5 may scan the deep ear canal. The inflatable membrane may also deformthe concha by inflating the inflatable membrane 110 to a predefinedpressure or until a predefined deformation of the concha is achieved.

FIG. 6 is a diagram illustrating membrane-less determination of thedistance to a proximal location 610 of an inner surface 620 of the ear,in accordance with some example embodiments. FIG. 7 is a diagramillustrating membrane-less determination of the distance to a distantlocation 710 of an inner surface 620 of the ear, in accordance with someexample embodiments. The light source may comprise a red LED providingred wavelength light 630, and a green LED providing green wavelengthlight 640. Any differing wavelength of light may be used. The lightsource may emit light that reflects from the actual tissue of theinterior surface of the ear (i.e. no inflatable membrane 110). Similarto that described above, because the absorbing medium may absorb, forexample, red and green light differently, the reflected red and greenlight from portion C 610 may be received, detected, and represented as aratio of intensities, such as detected red wavelength intensity over thedetected green wavelength intensity. Meanwhile, as shown in FIG. 7 thereflected red and green light from portion D 710 may be received,detected, and represented as a ratio of intensities as well. Given thatthe distance from portion D 710 to the distal portion of the scanningtip 320 (where the light receiver is located) is greater than thecorresponding distance between portion C 610 and receiver, the medium310 has a greater attenuating effect on the reflected light from portionD 710 as shown by the inset graphs. However, secondary reflections maybe a source of noise for the measurement. In some embodiments, theselection of wavelengths used can reduce this noise.

FIG. 8 is a diagram illustrating an exemplary reflectance spectra 810 ofa portion of an ear, in accordance with some example embodiments. Insome embodiments, selection of the two different wavelengths of lightmay be chosen such that their reflectance from the interior surface ofthe ear is low. For example, when the reflectance of the tissue is low,then each subsequent reflection reduces the intensity by a factor of1/R, where R is the reflectance. Combined with the absorbing propertiesof the medium 310, this preferentially attenuate the light received atthe detector that was not due to the primary reflection from the pointwhose distance from the detector is being determined. FIG. 8 shows, forexample, that the a first wavelength may be selected, for examplecorresponding to green light within band 820 and a second wavelength maybe selected, for example corresponding to red within band 830, so thatthese bands 810 and 820 are located where the reflectance due to thetissue on the surface of the cavity 330 is at a first minima 830 or at areduced reflectance 840 relative to another portion of the spectra. Inthe example of FIG. 8, the reflectance from the tissue on the surface ofthe cavity 330 also contains a maxima 850, so the reflectance from thetissue at this wavelength may contribute to noise or interference at thedetector. In some example embodiments, the scanning tip 320 may includea green light source in the range of 475-505 nanometers and a red lightsource in the range of 655-700 nanometers.

Although some of the examples described herein refer to using twowavelengths at red and green, other wavelengths may be used as well. Forexample, the intensity of other wavelengths of light can be detected atthe scanning tip 320 and then measured and compared may include ancombination of the following: violet light (approximately 380 to 450nm), blue light (approximately 450 to 495 nm), green light(approximately 495 to 570 nm), yellow light (approximately 570 to 590nm), orange light (approximately 590 to 620 nm), and/or red light(620-750 nm).

FIGS. 9A, 9B, and 9C are diagrams illustrating a serial linkage betweena structured light source 910 and camera 920, in accordance with someexample embodiments. When making multiple scans with the same scanner ordifferent types of scanners, the scanners can be rigidly coupled, madeintegral, or otherwise mechanically joined so that the relative positionof each scanner is known when combining the resultant scan images.

The 3D scanner 120 such as the scanner disclosed in FIGS. 1-5 may beused to scan the deep ear canal. A structured light source/cameraassembly 940 integrating the structured light source 910 and camera 920is also depicted in FIGS. 9A, 9B, and 9C. A mechanical linkage betweenthe structured light source/camera assembly 940 and the 3D scanner 120may provide more accurate position information for the scan data. Forexample, a serial linkage may be used between the structured lightsource/camera assembly 940 and the 3D scanner 120. The serial linkagemay include mechanically coupling the 3D scanner 120 to the structuredlight source/camera assembly 940 where both may also mechanicallycoupled to a robotic arm 950 or other gantry. The robotic arm 950 may beconfigured to monitor the position and orientation of the coupled 3Dscanner 120 and structured light source/camera assembly 161. Forexample, the 3D scanner 120 may be used to scan a portion of the ear.Then, the structured light source/camera assembly 940 may be translatedby the arm into position to scan the same (or different) portion of theear. Combining the data on the positions of each type of scanner whenthe scan was made may allow the spatial data or generated 3D surfacesfor the two scans to be synchronized for combination to form a compositescan.

In some example embodiments, the concha region may be scanned using astructured light source 920 and a camera 910 without deforming theconcha. Methods described herein that do not rely on physical contactbetween the scanning implement and the surface being scanned can avoidthe creation of artifact or other distortions in the measurements of thescanned surface. In some example embodiments, a scan of the ear canalincluding the deep ear canal and the concha may include two scans; onewith the 3D scanner 120 and another scan performed using structuredlight and/or direct imaging by a camera. The two scans can be alignedand merged using common locations at or near the aperture of the earcanal and interpolate/smooth the transition between the two surfaces inthe scans. For example, the two scans may be merged by a design computerto produce a combined scan or model of two or more scanned surfaces orshapes. In some implementations, the camera 920, detector, or otherimaging receiver may include a stereoscopic camera or optical system. Astereoscopic camera may enable 3D images to be acquired without havingto use structured light or an inflatable membrane 110. However, someimplementations can combine the stereoscopic camera with any of theother imaging techniques described herein.

FIGS. 10A, 10B, and 10C are diagrams illustrating imaging a 3D object1010 with a structured light source 910 and camera 920, in accordancewith some example embodiments. A camera 920 may image an objectilluminated by structured light source 910. Geometric details of theilluminated object can be determined from the image as shown by theexample of a hemisphere 1020. A structured light source may includeillumination that is patterned or includes some form of spatialvariations in intensity, wavelength, frequency, phase, or otherproperties of the light. By generating a predictable and predefinedpattern of light on the surface to be scanned, the images of the patterncan be analyzed to determine distance or other surface features. Forexample, a structured light source may include a series of alternatinglight and dark bars, although other patterns may also be used. In someexample embodiments, features of a three-dimensional object may bedetermined from the projection of the structured light onto the object.In one example, the projection onto the hemisphere 1020 of thealternating bars of light and dark causes the bars to appear wider dueto the hemispherical shape when viewed from the side. FIG. 10C alsoillustrates an example of an image showing a structured light pattern onthe surface of a person. The structured light pattern generated insidethe ear may be similar to the appearance of the structure light patternon the person.

In some embodiments, the camera 920, or other detector, can detectstructured light generated from a pattern imprinted on an interiorsurface of the inflatable membrane 110. For example, dots, lines, grids,or other visual patterns can be present on the inflatable membrane 110prior to scanning. The pattern may be illuminated to generate structuredlight from the interior surface. In other embodiments, the emitter canemit structured light to form a pattern on the interior surface of theinflatable membrane 110 conforming to an interior shape of an ear anddetecting the structured light generated by reflection from the interiorsurface. These may be done without using the medium 320 by, for example,inflating the inflatable membrane 110 with air or other uniformlyattenuating material. Once the light is detected, the light can beanalyzed as described herein to identify the shape of the scannedsurface.

FIG. 11 is a process flow diagram illustrating combining a scan from a3D scanner 120 and another scan from a structured light source andcamera, in accordance with some example embodiments. At 1110, a firstscan of an ear may be taken using a 3D scanner 120 such as the scannerdescribed in FIGS. 1-5. At 1120, the scan may be adjusted and/orprocessed to determine a shape of the ear canal. At 1130, another scanof the ear may be taken using a different type of scanner. For example,the structured light/camera assembly 940 may be used to generate asecond scan. At 1140, the second scan may be adjusted and/or processedto determine a shape of the concha. In some example embodiments, thefirst scan and the second scan may be performed together at the sametime. In some example embodiments, one scanner may perform both scans.For example, a 3D scanner 120 and a structured light source/cameraassembly 940 may be combined into a single scanner. At 1150, the scanfrom the 3D scanner 120 and the scan from the structured lightsource/camera assembly 940 may be aligned with one another. For example,the position of first scan relative to the second scan may be adjustedso that a region of the ear captured by both scans may be used to alignthe two scans. After alignment, at 1160, the two scans may be merged.

In some example embodiments, the scans may be merged where theoverlapping portions of the scans correspond to a transition region fromone scan to the other scan. In some example embodiments, the scans inthe transition region may be averaged with the scans being assignedequal weighting, or different weightings to preferentially bias thecomposite scan towards one scanning technique. For example, some methodsdescribed herein involve contact between the surface of the ear beingscanned and any foreign object, such as the inflatable membrane 110.Because methods involving contact can cause mechanical deformation ofthe surface, this can introduce an error in measurement. When combiningscans, methods that do not involve contact (such as membrane-less scansusing a structured light source) may be biased to have greater weightthan scans that did involve contact. The weighting may be on apixel-by-pixel basis, such as based on a measurement or estimate of theamount of deformation of the ear surface, or can be constant over allpixels for the given scan type. The weighting may be applied to anyinterpolation/smoothing algorithms or be indicated graphically to a usermanually merging the scans with modelling software.

In other embodiments, when the scans do not overlap, interpolationbetween the scans may be used to combine the scans. In anotherembodiment, one or more scans can be extrapolated to extend theeffective scan surface. In other embodiments, the scans may be combinedwith input from an operator visually aligning the individual scansrendered on a computing device.

In other example embodiments, based on the electronic representation 200or scans from either or both of the 3D scanner 120 and a structuredlight source/camera assembly 940, native references in the ear can beidentified. Native references can be specific portions of the earanatomy, for example, a concha, eardrum, or the like. Native referencescan also be specific contours of any portions of the ear anatomy. Thenative references may be referenced by the processor to facilitatecombining scans by providing common points of reference. In someembodiments, this can be used with the structured light source/cameraassembly 940 generating electronic representations of the ear where, dueto the method not requiring the inflatable membrane 110, no deformationof the interior surface of the ear is performed.

FIG. 12 is a diagram illustrating an example transition region betweenexample scans from a 3D scanner 120 and a structured light source 930and camera 920, in accordance with some example embodiments. Depicted at1210 are example scans for the right and left ear canals from aconformal membrane scanner (also referred to herein as a 3D scanner 120)such as a scanner consistent with FIGS. 1-5. Depicted at 1220 areexample scans for the right and left ears from another scanner such as astructured light source/camera assembly 940 disclosed in FIGS. 9-10.Depicted at 1230 are transition regions for the right and left ears. Thetransition regions may correspond to areas where the scan from the 3Dscanner 120 and the scan using the structured light source 930 andcamera 920 overlap. In some example embodiments, the transition regions1230 may be determined using interpolation, or averaging, or otheranalytical method of merging the two scans. In some example embodiments,the transition regions 1230 may be adjusted by an operator. In regionswhere no scan was available, and interpolated, extrapolated, orotherwise synthetic data was used to merge actual scan surfaces, anindication of the transition region 1230 may be indicated with differentcolors, patterns, or other visual indicators.

In other implementations, a second scanner, or a second scan from the 3Dscanner 120, may generate a second electronic representation of a secondshape. The second shape may include a second interior shape of a portionof the cavity, a second portion of a second surface proximate to thecavity, or the like. The second interior shape can be another part of anear or any other portion of the cavity 310. Similarly, the secondportion of the second surface can be part of an area outside the cavity,such as the concha of an ear or other nearby external structural featureof the object being scanned. The second scanner can be, for example, the3D scanner 120, a structured light source 910 and camera 920, or a laserrangefinder.

FIGS. 13A and 13B are diagrams illustrating examples of earbud adapters1300, in accordance with some example embodiments. The earbud adapter1300 may have an adapting portion 1310 to fit a commercial earbud orother earbud. Earbud adapter 1300 may have a customized portion 1320custom-produced to fit a particular person's ear based on the scan. Thecustomized portion 1320 may comprise a soft and/or flexible material.The adapting portion 1310 may comprise the same material or a differentmaterial. A right/left earbud adapter 1330 is shown coupled to acommercial earbud. A left/right earbud adapter 1340 is shown coupled toa commercial earbud is shown. The right and/or left earbuds may becolored so to distinguish the right and left earbuds/earbud adapters.

In accordance with some example embodiments, an earbud adapter 1300 maybe made from a flexible material such as silicone. The earbud adapter1300 may be produced from a scan performed on the ear canal to measurethe size and shape of the ear canal. In some example embodiments, thescan may also determine the shape of the concha and/or other externalear shape. The earbud adapter 1300 may be made to fit the measuredshape. The measured shape may be adjusted to reduce the length of theearbud in the ear canal, adjust the shape of the earbud on the surfaceoutside the ear, and/or to change the shape to adapt the earbud to astandard earbud, or any other commercial earbud.

The fabrication process for earbuds or in-ear headphones may includeadding speakers that may be wired devices or may be wireless devices.The additional components, for example, the speakers or wires, can beadded by a second apparatus such as an automated manufacturing device. Awireless earbud may receive a signal transmitted from a cellular phone,music player or other electronic device. The sound generating devicesmay generate sound such as music or voice or may provide passive noisereduction and/or active noise cancellation. Passive noise reduction mayoccur due to the custom size and fit of the custom earbuds/earbudadapters and/or by a choice of the earbud material. For example, someearbud materials may provide more sound attenuation through the earbudthan other materials. Active noise cancellation may include causing thesound generating devices in the earbuds to cancel noise that passesthrough or around the earbud at the ear canal side of the earbud. Inthis way, noise may be reduced at the ear canal. In some exampleembodiments, active noise cancellation may be performed in addition tosound generation of music or voice that the user has selected. Forexample, active noise cancellation and sound generation may be used tocancel aircraft noise and provide the user with music or voice during aflight.

Other additional components that may be included as part of the earbudsmay include, for example, microphones, transmitters, receivers, padding,additional conformal adaptors to increase comfort or fit to the cavity330, or the like. Also, the additional components can include biometricscanners, sensors, computer processors, electronic components forconnected devices, or the like.

FIG. 14 is a process flow diagram illustrating a first process, inaccordance with some example embodiments.

At 1410, the ear canal may be scanned by a scanner consistent with FIGS.1-5. In some example embodiments, a second scanner consistent with FIGS.9-10 may be used to scan the concha or other outer region of the ear.After the first ear is scanned, the second ear may be scanned. In someexample embodiments, the shape of the ear canal and/or concha may beprovided electronically as a 3D model or array of 2D models of the ear.In some example embodiments, the shape of the ear canal and/or conchamay be determined from another source such as a magnetic resonanceimaging or other imaging. In some example embodiments, the shape and/ormodel of the ear may be included in an electronic medical record.

At 1420, an earbud design may be produced based on the scan. In someexample embodiments, the earbud design may include the scan after one ormore adjustments. For example, the length of the earbud in the ear canalmay be adjusted to be longer or shorter than the scanned ear canal. Insome example embodiments, the length or external shape at the exteriorof the ear may be adjusted. For example, the earbud may be adjusted inlength to protrude more or less from the ear canal. In some exampleembodiments, the adjustments may include adjustments to cause improvedattachment to the ear so that the earbud is less likely to fall outduring use. In some example embodiments, the adjustments may include anopening at the exterior of the earbud to adapt and hold into place astandard earbud and/or other earbud.

At 1430, the earbud design may be produced on a fabrication machine. Forexample, the earbud design may be produced on a three-dimensional (3D)printer. In some example embodiments, a 3D printer may fabricate a 3Dmechanical structure using one or more selectable materials. Forexample, a 3D printer may produce layers of material with selectableregions of the different materials. 3D printers may deposit regions ofmaterial that include polyamide, urethane, plastic, ceramic, metal,paper, wax, or other material. In some example embodiments, the earbuddesign may be produced on a 3D printer with the exterior regions of theearbud made using a shell of rigid material such as polyamide, urethaneor other material and with the interior volume made from anothermaterial such as wax. The polyamide or urethane shell can be formed to apredetermined thickness, for example, between 0.05 mm and 2 mm. In someexample embodiments, the removable material may have a lower meltingpoint than the rigid material, or may be soluble in a solvent in whichthe rigid material is not soluble. The rigid exterior region may bereferred to as an earbud shell. In some example embodiments, the waxfrom the interior of the earbud shell may be removed by heating theearbud shell and allowing the wax to drain out. For example, the wax maydrain out when the shell is heated due to gravity or draining may beassisted by applying air pressure or placing the shell in a centrifuge.In some example embodiments, after the interior material such as wax hasbeen removed, the earbud shell may be filled with a flexible materialsuch as curable silicone or other material. After the silicone has curedin the shape of the interior of the earbud shell, the shell may beremoved leaving the flexible earbud. The silicone or other flexiblematerial may have a hardness of approximately 15-75 shore or otherhardness. In some example embodiments, the earbud shells may be producedwithout a parting line for use one time. Earbud shells produced with aparting line may be used multiple times to make multiple earbuds. Insome example embodiments, digital light processing (DLP) may be usedinstead of or in addition to 3D printing. In some example embodiments,DLP may include exposing light to liquid resin to produce a desiredshape. In some example embodiments, DLP may result in solid objectswithout a shell and without the interior wax to remove.

At 1440, finishing steps may be performed on the flexible earbud. Insome example embodiments, the earbud may be marked or color-coded sothat earbuds may be easily identified and which earbud is for the rightear and which earbud is for the left ear. In some example embodiments,the earbud may be smoothed, marked, rinsed, cleaned, and/or prepared foruse.

FIG. 15 is a process flow diagram illustrating a second process, inaccordance with some example embodiments.

At 1505, an ear may be scanned to determine the internal and/or externalshape of the scanned ear. In some example embodiments, the scanning maybe performed using an optical scanner such as the scanner described withrespect to FIGS. 1-5. In some example embodiments, the scan may beperformed using a different type of scanner such as a photographicscanner, magnetic resonance imaging, dye enhanced, or other scanner. Insome example embodiments, the shape of the ear may be providedelectronically as a 3D model or an array of 2D models or images. Theshape/model may be part of an electronic medical record.

At 1510, the scan may be adjusted to change the length and/oraccommodate an earbud. In some example embodiments, the earbud designmay include the scan after one or more adjustments. In some exampleembodiments, the scan, or a mathematical or electronic model of thescan, may be adjusted using a design computer that may run 3Ddesign/modelling software, Computer-Aided Drafting/Drawing (CAD)software, or the like. The design computer can be configured to modifyone or more electronic representations into a three-dimensional shapecorresponding to at least a portion of the interior shape of the ear.For example, the length of the earbud in the ear canal may be adjustedto be shorter than the scanned ear canal. In some example embodiments,the length or external shape of the earbud at the exterior of the earmay be adjusted. For example, the earbud may be adjusted in length toprotrude more or less from the ear canal. In some example embodiments,the adjustments may include adjustments to cause improved attachment tothe ear so that the earbud is less likely to fall out during use. Insome example embodiments, the adjustments may include an opening at theexterior of the earbud to adapt and hold into place a standard earbudand/or other earbud.

At 1515, a shell or earbud may be produced on a fabrication machine fromthe modified electronic representation or scan. In some exampleembodiments, a 3D printer or digital light processing system may be usedto produce earbud shells. For example, a 3D printer may “print” ordeposit successive layers of material to produce a 3D object. Forexample, a 3D printer may deposit two materials in successive layerssuch as a hard or rigid material on outside surfaces to produce a shell,and another material that is removable in the interior such as wax thataids in supporting the shell as the layers are deposited. In someexample embodiments, the removable material may have a lower meltingpoint than the rigid material, or may be soluble in a solvent in whichthe rigid material is not soluble. The 3D printer may be controlled by acomputer to produce earbud shells in accordance with the scanned ear orthe adjusted scan of the ear. In some example embodiments, extrusion andsintering-based processes may be used. The 3D printed shells may beproduced by the 3D printer on a plate. The shells may then be cleaned orrinsed.

At 1520, the shell may be cured. For example, the shell may be curedover a time period with or without being heated in an oven.

At 1525, the shell may be released. For example, the earbuds may bereleased from a plate associated with the 3D printer.

At 1530, the shell may be cleaned and the inner wax material may bemelted and drained out of the shells. For example, the wax in the shellsmay be melted in the oven at a temperature such as 70 degrees Celsius oranother temperature for 45 minutes or another amount of time. The earbudshells with the internal wax removed may be cleaned using a solutionsuch as mineral oil, at a particular temperature for a particular amountof time. For example, the earbud shells may be cleaned with mineral oilat 70 degrees Celsius for 15 minutes. The shells may be further cleanedand/or rinsed with a second liquid such as water. The shells may bedried using compressed air and/or placing the shells in an oven at, forexample, 70 degrees Celsius.

At 1535, the shell may be filled with a flexible material. For example,the earbud shells may be filled by injecting silicone or anotherflexible material into the shells. The injected compound may be liquidbefore curing and solid after curing.

At 1540, the material in the shell may be cured to form the earbud. Insome example embodiments, the material in the shell may includesilicone. Pressure may be applied to the filled earbud shells by, forexample, a pressure pot. For example, the pressure pot may be held at apressure of 6 bars at a temperature of 85 degrees Celsius for 10minutes. After the material such as silicone in the shells has cured,the shells may be removed. In some example embodiments, shells madewithout a parting line may be removed by cracking them with an arborpress. In some example embodiments, shells made with a parting line maynot require cracking. In some example embodiments, a shell post may beremoved in a central portion of the earbud. In some example embodiments,a grinder may be used to finish the earbud to ensure smoothness andremove any excess material remaining from the silicone injectionprocess. In some example embodiments, the left and right earbuds may bemarked in order to tell them apart. For example, the right and leftearbuds may be marked with dyed silicone. For example, a small hole maybe made in each earbud and colored silicone added. Additional curing,cleaning, rinsing, and drying may be performed. In some exampleembodiments, the earbuds may be lacquered. A centrifuge may be used toensure the lacquer coating is thin. For example, the lacquered earbudsmay be placed in a centrifuge at 500 RPM a few seconds. In some exampleembodiments, the lacquered earbuds may be dried under pressure at 85degrees Celsius for 5 minutes.

At 1545, the earbud may be marked with an identifier. For example, eachearbud may be marked with an identifier to ensure that the correctearbud is sent to a user. The right and left earbuds may be marked usingdifferent colors so that the user can visually distinguish the rightearbud from the left earbud.

At 1550, the earbud may be shipped to a user.

Though the methods, apparatus, and systems are described herein withrespect to an earpiece and scanning an ear canal, these methods,apparatus, and systems may be applied to any cavity 330 or orificeassembly for scanning any suitable anatomical cavity 330. For example,the methods, apparatus, and systems can be used for scanning oral,nasal, renal, intestinal, or other anatomical cavities, and can involveassemblies designed for those anatomical cavities. Further, thesemethods, apparatus, and systems may be used with sensitive or fragilecavities that are not anatomical in nature, such as those made frombrittle, pliable, or otherwise delicate materials.

Without in any way limiting the scope, interpretation, or application ofthe claims appearing below, a technical effect of one or more of theexample embodiments disclosed herein is reusability of certaincomponents. Moreover, without in any way limiting the scope,interpretation, or application of the claims appearing below, atechnical effect of one or more of the example embodiments disclosedherein is that the medium providing assembly may be used for multiplescans, including for multiple patients. In some implementations, theabsorbing medium and medium providing assembly may be used for 10-15scans or more. Furthermore, without in any way limiting the scope,interpretation, or application of the claims appearing below, atechnical effect of one or more of the example embodiments disclosedherein is that the absorbing medium, and the system as a whole, may bemore likely to be shelf-stable, as it can be shipped without contactingthe inflatable membrane until just before scanning.

FIG. 16 is a process flow diagram illustrating a third process, inaccordance with some example embodiments.

At 1610, the 3D scanner 120 may scan an interior shape of a cavity 330.The scanning may include inflating an inflatable membrane with a medium310 to conform an exterior surface of the inflatable membrane 110 to aninterior shape of a cavity 330. For example, the 3D scanner 120 can becoupled to the inflatable membrane 110 as shown in FIG. 1.

At 1620, light can be generated from an emitter to illuminate theinterior surface of the inflatable membrane 110. For example, the lightmay illuminate fluorescent portions of the inflatable membrane 110,illuminate a pattern imprinted on the inflatable membrane 110, create astructured light pattern on the inside of the inflatable membrane 110,or the like.

At 1630, a detector may detect light emitted from the interior surfaceof the inflatable membrane 110. For example, the light may include afirst optical wavelength and a second optical wavelength. The firstoptical wavelength and the second optical wavelength may be generated bydifferential attenuation of fluorescing light from the inflatablemembrane, reflection of light from the inflatable membrane where thelight was first generated by a multiple-wavelength emitter, reflectionof light from a pattern on the inflatable membrane, or the like.

At 1640, a processor may generate a first electronic representation 200of the interior shape based at least on the detected light. For example,the first electronic representation 200 may be a 3D rendering generatedby computer software and processor that combines one or more surfacesimaged by the 3D scanner 120. The first electronic representation 200may be combined by interpolating or otherwise digitallyexpanding/merging image portions, acquired by the 3D scanner 120 orother scanning technique, into a composite image of the ear.

At 1650, a second shape proximate to the cavity 330 may be scanned togenerate a second electronic representation of the second shape. Forexample, the second shape may correspond to an outer part of the objectscanned, or be another scan that overlaps some or all of the interiorshape scanned with the 3D scanner or other scanning device.

At 1660, the design computer may modify the first electronicrepresentation into a three-dimensional shape corresponding to at leasta portion of the interior shape. For example, the modification mayinclude digital deformation of the first electronic representation,rotation, translation, or other adjustment performed in softwareautomatically or by a user.

At 1670, the design computer may generate a combined electronicrepresentation from the first electronic representation and the secondelectronic representation. For example, the combined electronicrepresentation may include interpolating, extrapolating, or otherwiseconnecting features of the first electronic representation and thesecond electronic representation.

At 1680, the fabricator may fabricate an earbud according to thecombined electronic representation. The fabrication process may includetranslating the combined electronic representation to instructions thatfor operation of a 3D printer or other fabrication machine. Thefabrication process can also include forming a mold based on thecombined electronic representation.

One or more aspects or features of the subject matter described hereincan be realized in digital electronic circuitry, integrated circuitry,specially designed application specific integrated circuits (ASICs),field programmable gate arrays (FPGAs) computer hardware, firmware,software, and/or combinations thereof. These various aspects or featurescan include implementation in one or more computer programs that areexecutable and/or interpretable on a programmable system including atleast one programmable processor, which can be special or generalpurpose, coupled to receive data and instructions from, and to transmitdata and instructions to, a storage system, at least one input device,and at least one output device. The programmable system or computingsystem may include clients and servers. A client and server aregenerally remote from each other and typically interact through acommunication network. The relationship of client and server arises byvirtue of computer programs running on the respective computers andhaving a client-server relationship to each other.

These computer programs, which can also be referred to programs,software, software applications, applications, components, or code,include machine instructions for a programmable processor, and can beimplemented in a high-level procedural language, an object-orientedprogramming language, a functional programming language, a logicalprogramming language, and/or in assembly/machine language. As usedherein, the term “machine-readable medium” refers to any computerprogram product, apparatus and/or device, such as for example magneticdiscs, optical disks, memory, and Programmable Logic Devices (PLDs),used to provide machine instructions and/or data to a programmableprocessor, including a machine-readable medium that receives machineinstructions as a machine-readable signal. The term “machine-readablesignal” refers to any signal used to provide machine instructions and/ordata to a programmable processor. The machine-readable medium can storesuch machine instructions non-transitorily, such as for example as woulda non-transient solid-state memory or a magnetic hard drive or anyequivalent storage medium. The machine-readable medium can alternativelyor additionally store such machine instructions in a transient manner,such as for example as would a processor cache or other random accessmemory associated with one or more physical processor cores.

To provide for interaction with a user, one or more aspects or featuresof the subject matter described herein can be implemented on a computerhaving a display device, such as for example a cathode ray tube (CRT) ora liquid crystal display (LCD) or a light emitting diode (LED) monitorfor displaying information to the user and a keyboard and a pointingdevice, such as for example a mouse or a trackball, by which the usermay provide input to the computer. Other kinds of devices can be used toprovide for interaction with a user as well. For example, feedbackprovided to the user can be any form of sensory feedback, such as forexample visual feedback, auditory feedback, or tactile feedback; andinput from the user may be received in any form, including, but notlimited to, acoustic, speech, or tactile input. Other possible inputdevices include, but are not limited to, touch screens or othertouch-sensitive devices such as single or multi-point resistive orcapacitive trackpads, voice recognition hardware and software, opticalscanners, optical pointers, digital image capture devices and associatedinterpretation software, and the like.

In the descriptions above and in the claims, phrases such as “at leastone of” or “one or more of” may occur followed by a conjunctive list ofelements or features. The term “and/or” may also occur in a list of twoor more elements or features. Unless otherwise implicitly or explicitlycontradicted by the context in which it used, such a phrase is intendedto mean any of the listed elements or features individually or any ofthe recited elements or features in combination with any of the otherrecited elements or features. For example, the phrases “at least one ofA and B;” “one or more of A and B;” and “A and/or B” are each intendedto mean “A alone, B alone, or A and B together.” A similarinterpretation is also intended for lists including three or more items.For example, the phrases “at least one of A, B, and C;” “one or more ofA, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, Balone, C alone, A and B together, A and C together, B and C together, orA and B and C together.” Use of the term “based on,” above and in theclaims is intended to mean, “based at least in part on,” such that anunrecited feature or element is also permissible.

The subject matter described herein can be embodied in systems,apparatus, methods, and/or articles depending on the desiredconfiguration. The implementations set forth in the foregoingdescription do not represent all implementations consistent with thesubject matter described herein. Instead, they are merely some examplesconsistent with aspects related to the described subject matter.Although a few variations have been described in detail above, othermodifications or additions are possible. In particular, further featuresand/or variations can be provided in addition to those set forth herein.For example, the implementations described above can be directed tovarious combinations and subcombinations of the disclosed featuresand/or combinations and subcombinations of several further featuresdisclosed above. In addition, the logic flows depicted in theaccompanying figures and/or described herein do not necessarily requirethe particular order shown, or sequential order, to achieve desirableresults. Other implementations may be within the scope of the followingclaims.

What is claimed is:
 1. A system comprising: a first scanner comprising:an inflatable membrane configured to be inflated with a medium toconform an exterior surface of the inflatable membrane to an interiorshape of a cavity, the medium attenuating, at a first rate per unitlength, light having a first optical wavelength, and attenuating, at asecond rate per unit length, light having a second optical wavelength;an emitter configured to generate light to illuminate an interiorsurface of the inflatable membrane; a detector configured to receivelight from the interior surface of the inflatable membrane, the receivedlight comprising light at the first optical wavelength and the secondoptical wavelength; a processor configured to generate a firstelectronic representation of the interior shape based on the receivedlight; and a design computer configured to modify the first electronicrepresentation into a three-dimensional shape corresponding to at leasta portion of the interior shape by correlating pixels of the firstelectronic representation with corresponding distance information fromthe first scanner to the inflatable membrane for each pixel.
 2. Thesystem of claim 1, wherein the corresponding distance information fromthe first scanner to the inflatable membrane is for groups of pixels. 3.The system of claim 1, wherein the design computer executes acomputer-aided design application.
 4. The system of claim 1, wherein themodification includes at least one of a digital deformation, a rotation,a translation, or another adjustment of the first electronicrepresentation.
 5. The system of claim 1, further comprising: a secondscanner comprising a structured light source and a camera, the secondscanner configured to generate a second electronic representation of asecond shape, the second shape being of at least one of: a secondinterior shape of a portion of the cavity; and a second portion of asecond surface proximate to the cavity.
 6. The system of claim 5,wherein the design computer is further configured to merge the firstelectronic representation and the second electronic representation intoa combined electronic representation of the interior shape and thesecond shape.
 7. The system of claim 5, wherein the design computer isfurther configured to merge the first electronic representation and thesecond electronic representation based on at least one or more nativereferences within the interior shape and the second shape.
 8. The systemof claim 5, wherein the second scanner is coupled to the first scanner.9. The system of claim 6, wherein the combined electronic representationcorresponds to a concha region of an ear and at least a portion of anear canal.
 10. The system of claim 1, wherein the object adapted toconform to the cavity is at least one of an earbud, an earpiece, or anearbud adapter.
 11. A method comprising: performing a first scan, withat least a first scanner, of an interior shape of a cavity, the firstscan of the interior shape comprising: inflating an inflatable membranewith a medium, the inflating of the inflatable membrane conforms anexterior surface of the inflatable membrane to the interior shape of thecavity; generating light from an emitter to at least illuminate aninterior surface of the inflatable membrane; detecting, at a detector,light from the interior surface of the inflatable membrane, the lightcomprising a first optical wavelength and a second optical wavelength;and generating, at a processor, a first electronic representation of theinterior shape, the generating being based at least on the detectedlight; modifying the first electronic representation into athree-dimensional shape corresponding to at least a portion of theinterior shape by correlating, at a design computer, pixels of the firstelectronic representation with corresponding distance information fromthe first scanner to the inflatable membrane for each pixel; andfabricating, at a fabricator, an object adapted to conform to thecavity, the fabricating based at least on the three-dimensional shape.12. The method of claim 11, wherein the fabricating comprises at leastone of: forming, based at least on the interior shape, a mold for theobject; and fabricating the object with a three-dimensional printer or adigital light processing system.
 13. The method of claim 11, furthercomprising, adding, with a second apparatus, one or more additionalcomponents to the object, the one or more additional componentscomprising at least one component for delivering sound to an areaproximal to the object.
 14. The method of claim 11, performing a secondscan of a second shape proximate to the cavity, the second scan of thesecond shape generating a second electronic representation of the secondshape.
 15. The method of claim 14, further comprising: identifying,based at least on the second electronic representation, one or morenative references within the interior shape and the second shape;generating, at the design computer, based at least on the one or morenative references, a combined electronic representation comprising thefirst electronic representation and the second electronicrepresentation; and modifying, at the design computer, the combinedelectronic representation into a three-dimensional shape correspondingto at least a portion of the interior shape.
 16. A system comprising: afirst scanner comprising: an inflatable membrane configured to beinflated with a medium to conform an exterior surface of the inflatablemembrane to an interior shape of a cavity, the medium attenuating, at afirst rate per unit length, light having a first optical wavelength, andattenuating, at a second rate per unit length, light having a secondoptical wavelength; an emitter configured to generate light toilluminate an interior surface of the inflatable membrane; a detectorconfigured to receive light from the interior surface of the inflatablemembrane, the received light comprising light at the first opticalwavelength and the second optical wavelength; and a processor configuredto generate a first electronic representation of the interior shapebased on the received light; a second scanner comprising a structuredlight source and a camera, the second scanner configured to generate asecond electronic representation of a second shape, the second shapebeing of at least one of: a second interior shape of a portion of thecavity, and a second portion of a second surface proximate to thecavity; and a design computer configured to merge the first electronicrepresentation and the second electronic representation into a combinedelectronic representation of the interior shape and the second shape.17. The system of claim 16, wherein the second scanner further comprisesa laser rangefinder.
 18. The system of claim 16, wherein the structuredlight source emits light having spatial variations of intensity orwavelength.
 19. The system of claim 16, wherein the design computerexecutes a computer-aided design application.
 20. The system of claim16, wherein the design computer is further configured to merge the firstelectronic representation and the second electronic representation basedon at least one or more native references within the interior shape andthe second shape.
 21. The system of claim 20, wherein the one or morenative references comprises one or more specific portions of earanatomy.
 22. The system of claim 16, wherein the combined electronicrepresentation corresponds to a concha region of an ear and at least aportion of an ear canal.
 23. The system of claim 16, wherein the objectadapted to conform to the cavity is at least one of an earbud, anearpiece, or an earbud adapter.
 24. The system of claim 16, wherein thefirst electronic representation is generated based at least onmeasurements of absorption of the light at the first optical wavelengthand measurements of absorption of the light at the second opticalwavelength.
 25. The system of claim 16, wherein the inflatable membraneis inflated to at least one of a predefined pressure or until apredefined deformation of a concha is achieved.